Sprayer docking station and monitoring system

ABSTRACT

The improved sprayer system of the present invention utilizes a docking drogue and probe assembly to quickly and easily allow refilling of the sprayer tanks with a material from an enlarged nurse tank. The coupling of the drogue and probe allows for fluid communication, as well as electronic transmission of material data to a processor in the prime mover. This processor software also receives input regarding field data and crop data, as well as feedback data from the sprayer regarding the material application. A GPS system on the prime mover allows for tracking the spraying operation, while a time stamp in the processor software tracks the timing of the spraying operation. This system thus allows for accurate accountability and traceability for the use of materials during the spraying operation.

CROSS REFERENCE TO A RELATED APPLICATION

This application is a continuation of application Ser. No. 10/284,002filed Oct. 30, 2002 now U.S. Pat. No. 7,503,510.

BACKGROUND OF THE INVENTION Field of the Invention

Conventional sprayers, such as agricultural sprayers, typically carryone or more tanks for storing water or chemical solutions. A spray barhaving multiple sprayer heads is associated with the tanks for spraying,for example chemicals onto the crop in a field. When the sprayer tank isempty, the operator must drive back to the primary or nurse tank torefill the sprayer tank, and then return to the field to resume thespraying operation approximately where it was last interrupted.Generally, due to field size, it requires multiple sprayer tank fills tocomplete the spraying application for a given field. The refilling ofthe sprayer tank is a time consuming, manual process conducted by thesprayer operator using pumps, hoses, and judgment as to the neededamount of chemical solution and mix ratio. The time required to fill thesprayer tank significantly reduces the productivity of the machine.

The operator must use judgment to determine the volume of chemicals tobe put into the sprayer tank, since residual chemicals in the sprayertank must be dealt with after the spraying operation in the field iscompleted. To determine the amount, the operator must know or estimatethe amount of area which must still be sprayed and then accuratelymeasure the amount of water and chemicals to transfer to the sprayer.The operator also must use care to mix the proper ratio of chemicals towater in order to achieve the optimum spraying results. A mixconcentration that is lower than recommended by the chemical label willresult in poor pest control whereas, a mix that is too high inconcentration can result in crop or environmental damage. The mixing ofthe chemical is generally done by pouring the chemical into the top ofthe sprayer tank or into an induction device located on the sprayer oron the nurse tank which mixes the chemical into the water stream as thesprayer tank is filled. The operator may be subjected to chemicalexposure during the refilling process. Also, chemical spills may occurduring the refilling process, thereby contaminating the ground or thespraying equipment.

Recording of the chemicals used is also a function of the operator, whomust input data at the end of the spraying operation regarding theamount of chemicals used and the areas covered. This is also a timeconsuming process which often is ignored or overlooked, due to timeconstraints.

Therefore, a primary objective of the present invention is the provisionof an improved material handling and loading system for sprayers.

Another objective of the present invention is the provision of a dockingsystem which will allow the transfer of materials and data between aprimary or nurse tank and a sprayer tank to refill the tank withoutmanual intervention.

Another objective of the present invention is the provision of means anda method to electronically communicate data between the primary or nursetank and the sprayer, in order to control and record the loading processof the sprayer.

Another objective of the present invention is the provision of aspraying system that utilizes a computer processor and associatedsoftware for receiving and storing data regard loading of the sprayer.

Another objective of the present invention is the provision toelectronically trace the movement of the spray chemical in order tototally account for the chemical from its original container to itsfinal application location.

These and other objectives will become apparent from the followingdescription of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic flow chart of the improved spraying method of thepresent invention; and

FIG. 2 is a schematic side elevation view showing the drogue and probeassembly of the present invention used to fill the sprayer tank from anurse tank.

BRIEF SUMMARY OF THE INVENTION

The improved spraying system of the present invention utilizes a sprayerfor spraying materials from a sprayer tank onto a target area, such ascrop in a field. The sprayer may be pulled by a tractor or othervehicle, or may be self propelled. The material to be sprayed may be aliquid such as a chemical solution, a solid such as fertilizer, or a gassuch as ammonia. The system includes a data sensor and transmitter onthe sprayer to transmit sprayer data to a computer or processor on themachine or another remote location. The processor includes software forreceiving and ₅₋oring the sprayer data, as well as initial input dataconcerning the crop, the field, and the chemicals being used. Thissystem also includes a global positioning device for tracking thelocation of the spraying operation. The software includes a time stampfor time stamping the spraying data. Thus, accountability andtraceability of the use of the chemicals is automatically obtained.

The improved sprayer system also includes a drogue on the sprayer ortractor for coupling with a probe on the primary chemical storage ornurse tank. Upon coupling of the drogue and probe, the sprayer tank canbe automatically refilled with chemicals from the nurse tank, withoutmanually connecting hoses or activating pumps. This unmanned refillingprocess avoids chemical spills and exposure to the chemicals by theoperator. In addition to fluid communications, the coupled drogue andprobe provide electronic communication for automatically inputtinginformation to the processor regarding the refilling process. Othermaterial information can also be communicated between the sprayer andthe nurse tank. Navigation structure can be provided for guidancepurposes for locating the sprayer relative to the nurse tank and sprayerrelative to the crop. In a further embodiment, a direct trailer tosprayer wireless also can be used.

DETAILED DESCRIPTION OF THE INVENTION

The improved sprayer system of the present invention includes aself-propelled sprayer 10 with one or more material tanks 12 and one ormore spray nozzles 14 in connection with each tank 12. The sprayer alsomay be towed by a tractor. The sprayer 10 includes a pump (not shown)which can be actuated to cause material in the tank 12 to be sprayed bythe nozzles 14 onto a crop in the field.

The sprayer 10 includes a hose 16 for each tank 12 which is in fluidcommunication with a probe 18 extending forwardly from the sprayer 10.It is understood that the probe 18 may also extend rearwardly from thesprayer to allow for easy coupling, as discussed below.

A large primary storage or nurse tank 20 is provided for filling thetank 12 of the sprayer 10. The nurse tank 20 is mounted on a trailer 22,but it is understood that the nurse tank 20 may also be stationary onthe ground or on some other vehicle. A fluid line 24 leads from thenurse tank 20 to a pump 26. The pump 26 pumps water or a chemicalsolution via hose 24 through a flow meter 28 and to drogue 36, which isadapted to receive and couple to the probe 18. The drogue and probeassembly is similar to an in-flight refueling system for aircraft. It isunderstood that the probe and drogue may be reversed in respect to thesprayer and nurse tank if it is convenient to do so. Other automaticcoupling devices may also be used. Thus, when the drogue 36 and probe 18are coupled, water or a chemical solution in the nurse tank 20 can bepumped by a pump 26 or otherwise supplied to the tanks 12 on the sprayer10 while being precisely measured by flow meter 28. Coupling of theprobe 18 and drogue 36 is quickly and easily achieved by relative motionbetween the structures, such as by extending the probe 18 and/or drivingthe sprayer 10 forwardly. The enlarged open end of the drogue 36provides for easy alignment with the probe 18. The probe 18 can beextended from and retracted to the sprayer in any convenient manner.

A chemical storage tank 30 is also located on the trailer 22. Thechemical storage tank may be fixed or preferably easily detachable so asto accommodate the easy replacement of chemical storage tanks. Thechemical storage tank 30 is connected via hose 32 to hose 24. Thisallows chemical to be fed into hose 24 by way of flow meter 34 allowingprecise measurement of the flow of chemical. It is understood thatmultiple chemical storage tanks such as shown at 30 a and 30 b may beincluded in the system.

The drogue 36 and probe 18 also include electrical connections 39 suchthat upon coupling of the drogue and probe, data related to the fillingoperation, including, but not limited to the volume and type of materialsupplied from the nurse tank 20 and the chemical tank 30 (or tanks 30 a,30 b) to the sprayer tanks 12 can automatically be shared by sprayerdata processor 40 and the data processor 38 on the nurse trailer 22.Additional data can be input or transmitted to the sprayer processor 40and the nurse trailer processor 38, such as the site and size of thefield to be sprayed, the type of crop planted in the field, and sprayingoperation data. Such data can include information on material type anduse requirements to predict sprayer and nurse tank refilling needs sothat advanced notice can be provided to the operator and/or to thematerial supplier. The global positioning systems 50 and 52 can be orinclude a direct trailer to sprayer wireless communication link toeliminate any need for the electrical contacts 39 in the drogue andprobe and to provide, a direct communication link between the trailerand the sprayer during spraying operations. Auto-guidance of the sprayer10 and/or the mating coupling components 18 and 36 can also be providedby the processors 38 and 40 during the docking function.

The input means for the crop, field, material and spraying operationdata, as well as the GPS data, includes convention sensing andtransmission devices, both manual and automatic. Thus, the operator canmanually enter the crop, field, and material data into the processorwhile the spraying and GPS data is automatically input into theprocessor 40. The sprayer 10 also may be equipped with a globalpositioning device 50 operatively connected to the processor 40 so thatthe location of the sprayer 10 can be continuously and accuratelymonitored. The nurse tank 20 may also be provided with a globalpositioning system, as indicated by reference numeral 52 in FIG. 1. Thenurse trailer processor 38 is also operatively connected to theprocessor 40, via the electrical connections 39 in the drogue 36 andprobe 18.

In operation, the self-propelled sprayer 10 follows the steps generallyoutlined in FIG. 1. Specifically, the field data, crop data, andchemical application data are entered or recorded into either thesprayer processor 40 or nurse tank processor 38, as selected by theoperator. The chemical application data may include the type ofchemical, the mix ratio, and the target application rate for the job.The drogue 36 and probe 18 are coupled automatically as the sprayermoves toward the nurse trailer. The processors 38 and 40 calculate thecorrect volume of materials necessary such as chemicals and waterrequired for the application. By monitoring the flow meters 28 and 34and controlling the pump 26 and various valves (not shown), the preciseamount is transferred to the sprayer tank 12. An electronic record ofthe transferred amounts can be stored in the processors 38 and 40. Thesprayer 10 can then move away from the nurse trailer 22 with the probe18 and drogue 36 automatically disconnecting. The entire fillingoperation can be accomplished without the sprayer operator leaving thecab of the sprayer and without any other support person with the nursetrailer 22. The spray pumps are actuated and the sprayer 10 traversesthe field in a conventional manner, while the GPS 50 automaticallytracks the spraying operation and the spraying data is automaticallytransmitted to the processor 40 for recording. The material applicationrate may vary over the field in response to the input data provided tothe processor 40. When the tank 12 approaches a refill condition, thesystem will generate a visible and/or audible signal so that theoperator can return to the nurse station for refilling the tank 12. TheGPS 50 allows the operator to know exactly where to return to restartthe spraying operation, without overlapping the material application andwithout missing a portion of the field to be sprayed. The GPS system mayalso allow for an unmanned spraying operation wherein the tractortraverses the field without an operator.

The nurse tank 20 may also include a prime mover and a navigation system(not shown) coupled to the GPS 52 and in communication with thenavigation system on the sprayer 10 so that in the un-manned mode, thenurse tank will be guided to a precise refill location dependant onrefill needs of the sprayer and on other considerations, such as fieldor crop conditions. The nurse tank can also communicate with a main basestation or material supply company regarding nurse tank refill needs.

The software of the processor 40 also includes a time stamp, so that thetime of application of the materials to any particular area in the fieldcan be recorded.

Thus, the operator can use precision farming methods to provide accurateand detailed information regarding the type of material desired, the mixratio, the field size, the area covered, the position where materialapplication was terminated, and refill of the sprayer tanks, all fromthe driver's seat in the sprayer 10. This system provides moreefficiency, reduced contamination of the environment, equipment andpersonnel, precise measurements, reduced losses, and the capability formultiple material applications. The system also provides an advancenotice for refilling of the sprayer by the operator and of the nursetank by the operator or material supply company, as well as a convenientplanning and material tracking tool.

Thus, the improved sprayer system of the present invention yieldsincreased productivity and decreased hazards in the application ofmaterials to a crop in a field and other locations.

Whereas the invention has been shown and described in connection withthe preferred embodiment thereof, it will be understood that anymodifications, substitutions, and additions may be made which are withinthe intended broad scope of the following claims. From the foregoing, itcan be seen that the present invention accomplishes at least all of thestated objectives.

1. A method of monitoring spraying of a material by a sprayer onto cropsin a field, comprising the steps of: inputting field, crop and materialdata into a computer; spraying the field; refilling the sprayer withmaterial, the step of refilling including automatically coupling a nursetank to the sprayer; during the step of refilling, automaticallyrecording data regarding material flow to and from the sprayer into thecomputer; and auto-guiding the sprayer with a processor when couplingthe nurse tank to the sprayer as the sprayer moves toward the nursetank.
 2. The method of claim 1 further comprising the steps of providinga nurse tank processor, and communicating data between the nurse tankprocessor and the computer during the step of refilling.
 3. The methodof claim 2 further including the step of automatically connecting theprocessor and the computer.
 4. The method of claim 1 further comprisingtracking the location of the spraying operation and, after the step ofrefilling the sprayer, guiding the sprayer to a location where sprayingwas stopped for the step of refilling.
 5. The method of claim 4 furthercomprising coordinating the tracking and recording functions.
 6. Themethod of claim 5 further comprising time stamping the recorded sprayingdata.